During the operation of the OTC DAIHEN Welding Robot, if the system experiences problems such as welding control exception, welding mode setting error, or sensor function execution failure, the teach pendant will usually display a hardware and control-level alarm in the 5115 to 5203 range. If these faults are not investigated promptly, they may cause serious operational safety hazards or damage to core components such as the reducer.
To help on-site engineers and mechanics quickly locate problems, we have organized the diagnostic terminology from the official maintenance manual to provide you with the following intuitive fault quick reference table. We recommend using the search function, entering the error code (e.g., 5115), to accurately obtain troubleshooting and processing suggestions.
I. OTC Robot Alarm Code Real-Time Quick Reference Table (5115-5203)
| Alarm Code | Fault Phenomenon | Fault Cause Analysis | Countermeasures & Solutions |
|---|---|---|---|
| 5115 | WCR OFF Pause Exception | WCR (Welding Current Cutoff) was not terminated within the time limit. | Check the signal of “WCR OFF Wait Time” from the welding constants and welding power source, and then reset the fault. |
| 5118 | Arc Start Command Error in Tool Change Setup Welding Power Source | One mechanism recorded AS commands more than twice. | Modify the task program, and then reset the fault. |
| 5130 | Welding Mode Option Not Set | Used a welding mode option that has not been set. | Set the welding mode option, no reset operation is required. |
| 5131 | Cannot Use Welding Mode Option | The welding mode setting is incorrect, and system memory protection prevents writing options. | 1. Cancel the system memory protection function; 2. Restart the system. No reset operation is required. |
| 5132 | Cannot Use Specified Mode | The welding unit does not support this specified mode. | Replace with a welding unit that supports this specified mode, no reset operation is required. |
| 5133 | Cannot Use Welding Mode Option | The welding mode setting is incorrect. | Restore the welding mode options on the welding mode option screen, no reset operation is required. |
| 5200 | Cannot Execute Sensor Function | Incorrect usage of sensor function was detected in the teaching program. | 1. Record the sensor search function after the movement step; 2. After recording the movement step, use the “CheckGo” function to confirm. |
| 5201 | Search Range Exceeded | The robot moved outside the search range. | Modify (increase) the search range or program to correct the error, no reset operation is required. |
| 5202 | Search Range Insufficient | The robot detected a touch state within the minimum search range. | Modify (reduce) the search range or program to correct the error, no reset operation is required. |
| 5203 | Deviation Range Exceeded | The robot moved outside the deviation range. | Modify (increase) the deviation range or program to correct the error, no reset operation is required. |
II. Get Professional Technical Support and Maintenance Services
When the robot frequently displays the above hardware-level alarms, and routine reset attempts are ineffective, do not forcefully pull the robot arm or repeatedly force restarts, so as not to cause secondary irreversible damage.
Contact Anhui Oujie for Technical Guidance
- System Recovery & Hardware Repair: Manager Fang
- Service Hotline (WhatsApp): 180-9663-1656
- Official Email: ahojotc@gmail.com